Apparatus for making wrought iron and steel plate



JV. MILLER Oct. 3, 1967 APPARATUS FOR MAKING WRQUGHT IRON AND STEELPLATE Filed March 2, 1965 3 Sheets-Sheet l 411 III I if a F/GE . A TQOct. 3, 1967 J. MILLER 3,344,843

APPARATUS FOR MAKING WROUGHT IRON AND STEEL PLATE Filed March 2. 1965 5Sheets-Sheet 2 Gaseous Film Gaseous Film Slug Film RATE OF CHANGE OFCONCENTRATION 5 RADIUS OF THE PARTICE FIG 6 INV EN TOR JORGE M/LLE/PEMU/0Q! as APPARATUS FOR MAKING WROUGHT IRON AND STEEL PLATE Filed March2, 1965 J. MILLER Oct. 3, 1967 3 Sheets-Sheet 5 MENTOR J01? GE M/LL EREMU/MW ATTORNEY United States Patent 3,344,843 APPARATUS FOR MAKINGWROUGHT IRON AND STEEL PLATE Jorge Miller, Carrera 10, No. 1964, Of.911, Bogota, Colombia Filed Mar. 2, 1965, Ser. No. 438,463 6 Claims.(Cl. 164-259) The present application is a continuation-in-part of myco-pending application Ser. No. 208,292, filed July 9, 1962, nowabandoned, and entitled, Method for Making Steel; Ser. No. 208,293,filed July 9, 1962, now Patent No. 3,201,105 and entitled, Method andApparatus for Making Steel; and Ser. No. 208,294, filed July 9, 1962,now abandoned and titled, Method and Apparatus for Making Wrought Ironand Steel Plate.

The present invention relates to an apparatus for making wrought iron,as well as steel plate, wherein a gaseous compound is jetted againstmolten metal to shatter the metal into particles which are directlyrecovered upon an endlessly moving wall.

The manufacture of wrought iron by conventional methods involves acomplexity of handling steps wherein wrought iron bars are intersectedand repetitively milled until plate of the desired characteristics isobtained.

In my co-pending applications Ser. Nos. 208,292 and 208,293, referred toabove, molten metal from a forehearth is poured directly into atrough-like jet of gaseous compound emanating from especiallyconstructed nozzles in a wall of the reaction vessel. The molten metalis thus shattered and dispersed in particle form throughout the reactionvessel and recovered as finished steel at the bottom of the vessel.According to the present invention, the shattered particles of moltenmetal are recovered upon a drum, belt or other endlessly driven meanspositioned at an end of the reaction vessel opposite the shatteringnozzles. As a result, wrought iron is directly formed, as the shatteredparticles are splattered upon the rotating drum or belt and this wroughtiron is carried as a sheet or plate to the outside of the refractory forsubsequent milling, or other finishing treatment, if desired.

Accordingly, it is an object of the present invention to provide amethod for continuously converting molten metal to wrought iron plate.

Another object of the present invention is to utilize an endlessrotatable wall means for recovery of metal plate from a reaction chamberwherein molten metal is subjected to jetting by gaseous compound.

yet additional objects of the present invention will become apparentfrom the ensuing specification and attached drawings, wherein:

FIG. 1 is a side elevation in section of a reaction vessel with airjetting and molten metal introductory nozzles at its closed end and arotatable drum at its open end;

FIG. 2 is a top view thereof;

FIG. 3 is an enlarged cross-section of a particle of molten metalshattered by a jetting gaseous compound, according to the presentinvention;

FIG. 4 is an enlarged sectional view of wrought iron plate recoveredfrom the surface of a rotating drum and comprising particles of iron 46,interspersed with slag 43;

FIG. 5 is an enlarged sectional view of steel plate recovered from anendless drum which has not been cooled;

FIG. 6 is a graph relating the rate of change of concentration to theradius of the particle in jetting of the gaseous compound according tothe present invention;

FIG. 7 is an enlarged perspective view showing the position of gaseouscompound jets in the reaction vessel; and

FIG. 8 is an enlarged perspective view of the troughlike jet created bythe gaseous compound nozzles and receiving the molten metal stream, theL-shaped side com See figuration of molten stream 14 indicating theauxiliary jet from orifice 28 as overcoming the vacuum effect created bythe jets from nozzles 22 and 24.

Numerous US. patents such as Hawkins (558,947); Hawkins et al.(949,474); Mottweiler (1,968,851); Ervin (2,341,704); and Brennan(2,864,137), as well as German Patent No. 907,654, disclose processesfor refining molten metal. However, this prior patented art fails toanticipate the novel results obtained by my method and suggestedapparatus, involving the introduction of gaseous compound through atrough-shaped nozzle and an auxiliary nozzle located at the line ofvacuum created by the opposing Walls of the trough-shaped nozzle,resulting in the recovery of shattered molten particles as metal plateup on an endlessly moving wall.

The method of both Hawkins and Hawkins et a1. is endothermic since theirsteam prohibits exothermic reaction. In addition, their concentratedjets of steam and air are located so as to be directed on only one sideof the dripping molten metal. The large area of contact between mygaseous compound and molten metal, resulting from the use of atrough-shaped jet, is obviously not present in either Hawkins or Hawkinset a1.

Ervin does not teach chemical reaction but rather proportions bydisintegrating to obtain the desired characteristics. Though the taperedholes 1e and 1 of Ervin are trough-shaped in configuration, no provisionis made for using my auxiliary jet, which, as explained above, preventsundesirable, incomplete spattering.

Mottweilers blast of steam also prohibits the desired exothermicreaction in the same manner as Hawkins and Hawkins et al. The MottweilerV-shaped recess and centrally located port for applying asphalt powderto mineral wool is structurally and functionally dissimilar from myprimary trough-shaped and auxiliary nozzles. The Mottweiler steamissuing from port 13 and slots 21 functions to create a suction efiectexerted in outlet 17, pipe 20 and chamber 26 causing the powder asphaltto be withdrawn. Obviously, my primary trough-shaped nozzle andauxiliary nozzle are not used to promote a suction effect upon thepoured molten metal.

Brennan, though disclosing the spraying of atomized molten metal againsta rotating member and drawing a sheet therefrom, is merely concernedwith changing the shape of material, not its characteristics as is truein my method. The sole purpose of atomizing in Brennan is to stripparticles from his bars, there being no chemical transformation present.

According to the present invention, the temperature and composition ofmolten metal are analyzed in order to compute the stoichiometry for thedesired conversion reaction. Then, a gaseous compound including oxygenis formed so as to conform to the stoichiometry of the desiredconversion reaction, and is jetted in cross-section into the furnace ata pressure sufiicient to shatter the molten metal into particles havinga diameter in the range of 10 to 1,000 microns. An example of such agaseous compound is CO as is referred to in my companion applicationSer. Nos. 208,292 and 208,293. The molten metal is then poured onto thegaseous compound so as to disperse shattered molten particles throughoutthe furnace. While the particles are being dispersed in the furnace,they undergo a series of highly exothermic reactions. One specificexample of making wrought iron according to this invention is asfollows:

Wrought iron containing less than 0.08% carbon in the metal withintermingled slag of iron and manganese silicates is to be made from amolten metal stream containing iron with 2.6% carbon, 0.2% manganese and2% silicon.

STOICHIOMETRY OF THE SYSTEM [Basisz 1 ton per hour molten metal,reaction temperature at jet impact 3,000 F.

Impurities reduction Percent Pounds per Moles per Moles oxidized Oxygenre- Minute Minute to quired,

C 2. 58 0.945 0.0787 CO 0.0474 0.0237 00 0.0313 0.0313 0. 2 0. 07340.00134 MnO 0.00134 0.0013 2.0 0. 734 0.0102 FeO 0.0102 7 0.0051 2. 0 0.734 0. 0262 SiO 0.0262 0.0262

Total Moles 0 requir 0. 0876 From the above chart, the ratio of CO to COin equilibis 0.659, thus:

Pressure of air jet to be within 30 to 110 lb. p.s.i., particle size 10to 1000 microns diameter.

A suggested apparatus for performing my method for making wrought irondisclosed herein is illustrated in FIG. 1 wherein a reaction vessel 10is shown as having a closed end 36 and an open end 34 in which rotatabledrum 38 is mounted. Drum 38 has a hub or core 42 and an annular space 40in which water or another fluid cooling medium may be circulated. An oilreservoir 56 and nozzle spray 58 are employed to lubricate the outersurface of drum 38 prior to its contact with the shattered moltenparticles. In addition, a mixture of oil, water and a small amount oflime will protect the surface of drum 38 from pitting by the shatteredparticles temporarily adhering thereto. In the closed end of vessel 10an entry port 18 is provided to support nozzle means 16 which terminatesin a slotted face plate 50, as illustrated in FIG. 8. Slots 22 and 24'of face plate 50 provide a trough-like jet into which -is poured moltenmetal stream 14 from fore-hearth 12.

Instantaneously, molten metal stream 14 is shattered and particles inthe range of 10 to 1,000 microns in diameter are directed towards theopen end 34 and against the surface of rotatable drum 38. The pattern ofshattered particles, moving towards the surface of drum 38, iscontrolled by auxiliary nozzles 28, 30' and 64. As will be aptrolled byauxiliary nozzles 28, 30 and 64. As will be apparent, this pattern isthicker at the bottom portion of the drum (point 60) where the rotatingsurface of drum 38 is withdrawn from exposure to the shattered metalparticles and is presented to pressing roller 54 and milling rollers 52.Due to the oil-like film upon the plate, there is no freezing of wroughtiron to the surface of drum 38. However, if the drum surface is notwatercooled, the effect illustrated in FIG. 5 occurs wherein theshattered molten particles freeze to the drum surface as a thin bottomlayer of slag, a middle layer of steel, and a thick top layer of slag.The desired wrought iron characteristics are illustrated in FIG. 4wherein iron particles 46, having slag particles 48 at their points ofintersection, present a unified wrought iron plate 44.

A pyrometer 32 may be employed to gauge the temperature of the gaseousreaction and enable stoichiometric proportioning of gaseous compound andmolten metal streams being introduced into the reaction vessel. Also, aplurality of secondary jets 64 may be positioned in the reaction vesselboth for guiding the shattered molten particles and for the introductionof exhaust gas from exhaust gas exit 30. The introduction of exhaust gasis in some cases desirable in order not to disturb the character of thereaction or to vary the composition of the gas. Needless to say, thepositioning of jets 28, 30 and 64 determine the pattern cast upon rotarydrum 38. Manifestly, and endless belt may be mounted at one end onrotary drum 38 and upon idler or driving roller at its other end,wrought iron plate 44 being formed directly upon the belt andsubsequently milled after removal from the reactor.

Also, according to the present invention powdered additives such assilica, nickel and lime may be interspersed with the gaseous compoundand introduced thereby via nozzles 64 or any of the secondary nozzles.This means of introduction of powdered additive would avoid bridging orslag formation on the fore-hearth 12, if the molten metal were pouredtogether with additives into the trough-like jet. Port 62 in the bottomof the vessel is provided for withdrawal of a small portion of moltenmetal not recoverable upon drum 38.

As a lubricant a mixture containing oil, water and a small portion oflime will avoid pitting of the drum 38 surface by the shatteredparticles temporarily adhering thereto.

Manifestly, numerous changes in my method may be employed withoutdeparting from the spirit and scope of the invention, as defined in thesub-joined claims.

I claim:

1. An apparatus for conversion of molten metal into plate, comprising:

(A) a reactor having an entry port at a closed end thereof and anexhaust gas exit port at an open end thereof;

(B) cupola fore-hearth means for conveying said molten metal to saidreactor; I

(C) gaseous compound primary nozzle means supported in said entry port,said primary nozzle means having opposed sides for emitting atrough-like jet beneath said molten metal falling from said forehearthinto said reactor, and an auxiliary gaseous compound nozzle co-axiallydisposed with respect to the line of maximum vacuum created by saidopposed sides of said trough-like jet;

(D) means directing said gaseous compound through said nozzles at apressure sufiicient to shatter said molten metal into particles having adiameter in the range of 10 to 1,000 microns; and

(E) endless rotatable wall means positioned at said open end of saidreactor opposite said primary nozzle so as to recover shattered moltenparticles and remove said particles from said reactor as metal plate.

2. Apparatus as in claim 1, wherein said rotatable wall 'means is awater cooled rotatable drum positioned so that its path of rotationextends both into and outside of said reactor.

3. Apparatus as in claim 1, wherein said rotatable wall means is anendless belt rotatable about a roller positioned at said open end ofsaid reactor so that a portion of said belt is continuously movedthrough the open end of said reactor.

4. Apparatus as in claim 3, including a milling means positioned oneither side of said belt so as to mill said metal plate subsequent toits removal from said reactor.

5. Apparatus as in claim 1, including a plurality of secondary nozzlespositioned in said reactor intermediate said primary nozzle means andsaid endless rotatable means for introducing gaseous medium therein anddefining the area of impact of said shattered molten particles upon saidrotatable means.

6. Apparatus as in claim 5, including means for introducing exhaustgases into at least one of said secondary jets.

References Cited UNITED STATES PATENTS Rand n n '75--60 Hawkins 7560Hawkins et a1. 7552 Mottweiler -5 Ervin 264-12 Brennan 2257.3 Haussneret al. 22-57.3

Hamilton 2-2200.1 'Littlewood et al. 22--57.3 Charlton et al 2220O '.1Miller 60 X Matvay 117-105.1 X

J. SPENCER OVERHOLSER, Primary Examiner.

1. AN APPARATUS FOR CONVERSION OF MOLTEN METAL INTO PLATE, COMPRISING:(A) A REACTOR HAVING AN ENTRY ORT AT A CLOSED END THEREOF AND AN EXHAUSTGAS EXIT PORT AT AN OPEN AND THEREOF; (B) CUPOLA FORE-HEARTH MEANS FORCONVEYING SAID MOLTEN METAL TO SAID REACTOR; (C) GASEOUS COMPOUNDPRIMARY NOZZLE MEANS SUPPORTED IN SAID ENTRY PORT, SAID PRIMARY NOZZLEMEANS HAVING OPPOSED SIDES FOR EMITTING A TROUGH-LIKE JET BENEATH SAIDMOLTEN METAL FALLING FROM SAID FOREHEARTH INTO SAID REACTOR, AND ANAUXILIARY GASEOUS COMPOUND NOZZLE CO-AXIALLY DISPOSED WITH RESPECT TO